PANKAJ SAINI

Present Address

#2484, Sector-39C
Chandigarh, INDIA
Mobile: +91-7676192448, Email: pankaj0884@gmail.com

Key words: 6+ yrs /MSC Patran/Nastran/Hypermesh /ANSYS/ CAE/Airframe

design & Analysis/ Catia V5

Objective
To excel in the field of Structural Design & Analysis and to grow along with the
organisation by utilizing my skills and capabilities

Profile Summary

 Total 6 plus years experience in Mechanical Design & Analysis of aerospace,

industrial structural components.
 Good in Airframe theoretical design calculations.
 Finite element analysis of airframe components by using MSC.Patran and
MSC.Nastran and Hyperworks.
 Able to read 2D Drawings and carry out the conversion of 2D drawings into 3D
modelling using CAD Packages.
 Proficiency in using Microsoft packages like Excel, Word & Power Point for Stress
Analysis Projects
 Possess excellent communication, analytical and relationship management skills.
 Ability to work in-group as well as independently with minimal supervision.
 Ability to learn new languages and tools quickly and efficiently.
 Basic knowledge of Excel VBA coding.

Professional Qualifications

B.Tech (2002-06) in Mechanical Engineering from Punjab Technical University with an

aggregate of 70.7%

Professional Skills

CAE software: Nastran, Patran, Hypermesh, ANSYS

CAD software: Catia V5, AutoCAD

Work Experience
Current Employer: Ausy Technologies India
Designation: Senior CAE Engineer
Tenure/ Duration: June 2013 – Till Date

AUSY group is global leader in providing engineering across various verticals and
having worldwide presence. Ausy Technologies India is providing engineering
consultancy services for prestigious aerospace companies such as Airbus, Embraer,
and EADS.

Currently working on a project that involves static, dynamic, harmonic, impact &
buckling analysis of fuselage assembly platform for Embraer KC390 aircraft. The above
calculations are performed on ANSYS workbench
 PANKAJ SAINI
Employer: Capgemini India
Designation: Consultant
Tenure/ Duration: May 2012 – June 2013

Capgemini is global leader in providing engineering and IT services across various

verticals and having worldwide presence. Through other subsidiary companies
Capgemini India is providing engineering consultancy services for prestigious aerospace
companies such as Airbus.

Roles and Responsibilities:

 Preparing estimation for stress related activities.

 Validation of aircraft structure for static strength and integrity.
 Preparing stress report after validation of margin of safety.
 Preparing best practices, lessons learnt and methodology/process documentation as
a part of continuous improvement.

Project 1) Static Strength Justification of Door Brackets and Ceiling

Attachments for A350-XWB

Duration: 4 months

Tasks Performed:

 Geometry cleanup, meshing of the components, assigning suitable material and

properties to the components using Hypermesh.
 Extracting loads from the Panel Interface locations and identification of load
application points on brackets.
 Creation of different load cases, applying the loads accordingly and creating suitable
boundary conditions.
 Preparing deck for SOL-101, SOL-103 and running the calculation in NASTRAN.
 Post processing the results in PATRAN and interpretation of results such as
deformation, stress values and mode shapes.
 Creation of detail stress report which includes the information about FEM model,
different materials, properties, various load cases, calculation for margin of safety of
different components with supporting images as per AIRBUS standards.
 Validating the fasteners, pins and lugs for different modes of failure.
 Performing modal analysis to identify different mode shapes and doing the wind
milling calculation.
Project 2) Static Strength Justification of lateral hatracks for A350-XWB

Duration: 3 months

Project Description: All the lateral hatracks located in FWD conical, Cylindrical and
AFT conical section of the fuselage had to be analysed for three different configurations
of C brackets to identify the most critical configuration and to calculate the allowable
load.

Tasks Performed:

 Geometry cleanup, mid surface extraction, meshing of rails, A,B and C brackets,
assigning suitable material and properties to the components using PATRAN.
 Creation of different load cases, applying the loads accordingly and creating suitable
boundary conditions.
 Preparing deck for SOL-101, SOL-103 and SOL-105 and running the calculation in
NASTRAN.
 PANKAJ SAINI
 Post processing the results in PATRAN and interpretation of results such as
deformation, stress values and mode shapes.
 Performing modal analysis to identify different mode shapes and doing the wind
milling calculation.
 Buckling calculation for the tie rods to calculate the buckling factor.
 Creation of detail stress report which includes the information about FEM model,
different materials, properties, various load cases, calculation for margin of safety of
different components with supporting images as per AIRBUS standards.

Project 3) Static Strength Justification of Exit Sign, IP Traverse brackets for

A350-XWB

Duration: 2 weeks

 Geometry cleanup, mid surface extraction, meshing of rails, A,B and C brackets,
assigning suitable material and properties to the components using PATRAN.
 Creation of different load cases, applying the loads accordingly and creating suitable
boundary conditions.
 Preparing deck for SOL-101, SOL-103 and SOL-105 and running the calculation in
NASTRAN.
 Post processing the results in PATRAN and interpretation of results such as
deformation, stress values and mode shapes.
 Preparing short stress reports containing margin of safety and fastener calculations.

Previous Employer: TAAL Technologies Pvt. Ltd., Bangalore, India

Designation: Senior Design Engineer
Tenure/ Duration: April 2010 –April 2012

TAAL Technologies is an Engineering Services and Technology Solutions company

helping global corporations in Aerospace & Defence, Power Generation, Oil & Gas
and Industrial Segments. TAAL Technologies provides solutions in Product Design
and Innovations, Product Enhancements, Value Engineering, Cost Reductions, Product
Optimization, CAD / CAE /CAM solutions, Process Planning, Concurrent Engineering,
Virtual Simulation and Manufacturing Optimization.

Roles and Responsibilities:

 Carry out Structure FEM Analysis using Nastran & Patran for Static, Dynamic &
Thermal requirements & Report writing.
 As a project engineer, work in a team spirit to achieve goals within the deadline
provided by client.

Project 1) Draw Carriage durability study using FEM approach

Tasks Performed:

Project Description: The structure was failing at a particular location frequently. The
aim of the project was to detect the cause of the failure ad suggest suitable design
change

Tasks Performed:

 Creation of finite element model for Draw carriage components, defining Boundary
conditions, Loads and material properties for analysis in MSC Patran.
 A linear static analysis has been carried out for the Draw Carriage. MSC Nastran was
used as the solver for this case.
 PANKAJ SAINI
 Stress Distribution and deformation pattern are recorded for the durability study and
necessary design changes were made.

Project 2) Interface Load Generation for AFT Side Closet Assembly for Embraer

Project Description: The aim of the project was to run the linear static analysis for
different inertia and abuse loads using PATRAN/NASTRAN and to extract the interface
load at the fitting locations and report it in the customer supplied format

Tasks Performed:

 The CAD model for the closet was imported and FE model was generated using mid
surface mesh.
 Assigning laminate material properties using PCOMP card using the material details
given by the customer.
 The loads and boundary conditions were applied to the closet assembly. The Model
was analyzed for various Inertia and abuse load cases.
 The Interface loads at various fitting locations were tabulated in the Excel Report.

Project 3) Structural Substantiation of Air Duct Assembly

Project Description: The Air Duct Assembly made of composite laminates was to be
analyzed for structural substantiation for different inertia and burst pressure load cases.

Tasks Performed:

 Generated the FE model, assigned laminate properties, defined load cases, BCs and
output variables.
 Carried out linear static analysis
 The Maximum principal stress, Min principal stress, Von-misses, Max shears stress is
noted from FEA.
 Calculation of Reserve Factor and Reporting.
 Also the Failure Indices were calculated according to Tsai-Wu Failure Criteria.
 Finally the Normal mode analysis was carried out to extract Eigen values and Eigen
vectors.
Project 4) Design Modification and Finite Element Analysis of Transport Joint
of UAV

Project Description: The existing transport joint was made in two halves of heat
treated EN-24 material (30 HRC) & strapped by two plates one each top & bottom with
two screws. These joints are designed to facilitate transportation where the outboard
wings are disassembled & assembled at launching site,. However it was experienced
that the joint design is such that the assembly process at site is not as desired, because
of number of parts involved. This modification incorporates single bolt joint, to make
assembly & disassembly simpler.
Tasks Performed:

 Generated the FE model, assigned laminate properties, defined load cases, BCs and
output variables.
 Analysis of modified joint for various flight loads such as Normal flight loads along
with pitching movement, Launch loads, Parachute deployment loads, Landing impact
loads In order to determine the deflection contours, stress distribution and stress
concentration on the brackets.
 Doing hand calculations to verify the results from FEA
 Recommended material change from Steel to Light Aluminium Alloy.
 PANKAJ SAINI
Project 5) Structural Analysis of Elevator of an Aircraft

Project Description: Carrying out linear Static and Buckling Analysis for the elevator
of small aircraft under Air loads

My role in the Project:

 The CAD model was imported and meshed using Hexahedral, Shell, CBAR and spring
elements. The composite material properties were assigned to the skin using PCOMP
bulk data entries and a chord wise varying load was applied.
 Linear static analysis was carried out and the displacement/stress plots and Ply
failure Indices are evaluated according to Tsai-Wu Failure Criteria
 Conclusions were reported and submitted to customer for approval

Project 6) Static Strength Justification and FEM Report of PAX(Passenger)

Floor Metallic Crossbeams for A-350XWB
Tools used: Hypermesh, Hyperview, MSC.Nastran, Microsoft-Office

Project Description: This report includes the static strength justification of the PAX
Floor Metallic Crossbeams in FWD Fuselage Section 13/14 of the A350XWB-900
MSN001. Each crossbeam is part of the principal sustaining structure of the PAX floor.
They have to withstand the ultimate static flight and ground loads, crash loads and
rapid decompression loads coming from the PAX floor and the fuselage. Forces and
deformations are extracted from the GFEM model using ISSY GMOD module and applied
to the DFEM model as forces and enforced displacements. Strength, Lateral stability and
Web Buckling is checked using MSC/Nastran. The DFEM model is validated as per Airbus
Standards and FEA report was prepared that contained the description of DFEM model.

Tasks Performed:

 The strength and stability of the crossbeams is checked DFEM analysis using
MSC/Nastran. Reserve factors (Strength and Stability) for all the crossbeams of FWD
Fuselage Section is calculated and Reported in the Certification Report.
 Running the macros to get the result images in Hypermesh and Hyperview to be
included in the Report.
 Doing Peer QC for other team members as per the Airbus guidelines.

Previous Employer: Synergy Thrislington Pvt.Ltd. Nalagarh,H.P

Designation: Design Engineer
Tenure/ Duration: May 2007 till August 2009
Synergy Thrislington is sheet metal units of Synergy Telecommunication Group
takeover of Thrislington (U.K). Company is leading manufacturer of highly hygienic
clean room partitions, doors & office partitions, fire doors used in Parma & office
industry. Company has state of art designing & manufacturing facility.

 Product development, R&D.

 Analysis of Mobile Towers & Structures using Finite Element approach.
 Analysis of Jigs & Fixtures & New Product Development.
 Preparation of Layout Models, Machine tools, Jigs & Fixtures using Catia-V5 &
AutoCAD.
 Preparation of technical drawings, specification sheets, BOQ’s.
 Vendor Development, Outsourcing, and sub-contractor co-ordination.
 Complete client co-ordination.
 PANKAJ SAINI
Previous Employer: Coatec India, Mohali
Designation: Design Engineer
Tenure/ Duration: May 2006 till March 2007
Coatec India is a renowned manufacturer of Automated C E D Coating, Phosphating,
Dip spin Coating plants in India, having manufacturing unit in Mohali.

 Complete client co-ordination.

 Preparation of technical drawings, specification sheets, BOQ’s
 Verification of drawings on AutoCAD software.
 Evaluated and adjusted new designs and detail drawings to ensure practical
completion while adhering to customer standards for usage and bottom line
expenditure
 Design & Development of prototypes using Catia-V5.

Professional Training

1) Training in Aero-Structures Design & Structural Analysis from Bangalore Aircraft

Industries Pvt. Ltd. Bangalore from September-2009 till March-2010.
The training program is based on Bruhn`s Book & focuses on Aeroplane Wing design
using hand calculations and solving real life problems using Finite element Analysis
on software packages such as MSC-Patran and MSC-Nastran.
2) Undertook six months Industrial training at Cheema Boilers Ltd. Kurali,Punjab
3) Certification course in AutoCAD & Catia-V5 from CAD centre, Chandigarh.

Personal Information

Sex Male
Father`s Name Sh. Rameshwar Dass
Date of Birth 2nd August 1984
Nationality Indian
Marital status Single
Languages Known English, Hindi, Punjabi
Permanent Address H.No-2484, Sector-39C, Chandigarh.
Passport number G7326221
Valid till Feb 6th, 2018

Personal Traits

 A goal oriented and team focused person with ability to work on his own initiative.
 Adapt quickly to diverse management and client styles.
 Use positive attitude and high standards to motivate staff to excellence
 Fast learner.

References

Available Upon Request

Declarations

I hereby solemnly declare that all the information given above is true and correct to the
best of my knowledge and belief.

PANKAJ KUMAR SAINI DATE & PLACE